Cushioned casing for an underwire and method of manufacturing the cushioned casing

ABSTRACT

There is provided a cushioned casing for an underwire of a brassiere. The cushioned casing comprises a cushioning material and a structure for enclosing an underwire and the cushioning material. The structure comprises a body having a channel for receiving an underwire and a wing member integral with and extending from the body. The cushioning material is positioned on the outside of the body, and the wing member is folded around the cushioning member to capture the cushioning material between the body and the wing member. There is also provided a cushioned casing for an underwire of a brassiere comprising a cushioning material and a structure for enclosing an underwire and the cushioning material. The structure comprises an inner sleeve and an outer fabric layer. The inner sleeve comprises a longitudinal body having a channel for receiving an underwire.

CROSS-REFERENCE TO RELATED APPLICATIONS

Chinese patent application No. 201310272002.1 filed on Jul. 1, 2013 and Chinese patent application No. 201310430488.7 filed on Sep. 18, 2013 are incorporated herein by reference.

FIELD OF THE INVENTION

The present invention is directed to a cushioned casing for an underwire of a brassiere and its method of manufacture. In particular, the cushioned casing for an underwire has a cushioning material and a structure for enclosing an underwire and the cushioning material.

BACKGROUND

A brassiere may include an underwire for each breast cup to shape and support the lower periphery of each breast cup. A conventional underwire comprises a generally U-shaped wire formed from metal or a rigid plastic material. Usually a pair of underwires is incorporated into a brassiere or other undergarment to provide shape and support for a pair of breast cups.

It is known to provide a cushioning material along an underwire, on the side that faces a wearer of the brassier, to reduce the pressure and discomfort of an underwire against a wearer's body.

U.S. Pat. No. 8,113,909, which is hereby incorporated by reference in its entirety, discloses a cushioned underwire comprising an inner sleeve containing an underwire, a cushioning material covering the sleeve, and a panel of fabric that is wrapped around the cushioning material and sleeve to substantially cover the cushioning material. The sleeve and fabric panel together form a structure for capturing the underwire and cushioning material, and the structure and cushioning material together form a cushioned casing for an underwire.

It is an object of the present invention to provide an improved cushioned casing for an underwire and a method of its manufacture.

SUMMARY OF THE INVENTION

In accordance with a first aspect of the invention, there is provided a cushioned casing for an underwire of a brassiere comprising a cushioning material and a structure for enclosing an underwire and the cushioning material. The structure comprises a body having a channel for receiving an underwire and a wing member integral with and extending from the body. The cushioning material is positioned on the outside of the body, and the wing member is folded around the cushioning material to capture the cushioning material between the body and the wing member. By ‘integral’ it is meant that the body and wing member are formed of a single piece, for example formed by a single fabric piece.

In one embodiment, the structure comprises an integral three leaf structure, where two of the leaves are brought together to form the body having the channel and the third leaf is the wing member.

The cushioned casing may further comprise a film attached to the wing member on the side that contacts the cushioning material, such that the film is positioned between the wing member and the cushioning material.

Preferably, the wing member may be attached to the body.

In another embodiment, the structure may further comprise a protrusion extending from the body, wherein the cushioning material is positioned adjacent the protrusion, such that the cushioning material is enclosed between the wing member, the protrusion, and the body. The protrusion may be integral with the body. The wing member may be attached to the protrusion.

The cushioned casing may further comprise an underwire extending through the channel of the body.

In a second aspect of the invention there is provided a method for manufacturing a cushioned casing for an underwire of a brassiere, the method comprising: providing a structure comprising a body having a channel for receiving an underwire of a brassiere and a wing member integral with and extending from the body; positioning a cushioning material on the outside of the body having the channel; and folding the wing member around the cushioning material to capture the cushioning member between the body and the wing member.

Preferably, the step of positioning the cushioning material on the outside of the body further comprises attaching the cushioning material to the body

The method may further comprise attaching a film to the wing member prior to folding the wing member around the cushioning material.

The wing member has two ends, one integral with the body and the other a free end, and the method may further comprise attaching the free end of the wing member to the body.

The structure may comprise a protrusion extending from the body, and the step of positioning a cushioning material on the outside of the body may then comprise positioning the cushioning material adjacent the protrusion.

In a third aspect of the invention there is provided a method for manufacturing a cushioned casing for an underwire of a brassiere, the method comprising: providing an integrated structure having three leaves, each leaf having an end joined to the other leaves and a free end; positioning a cushioning material on a first leaf of the three leaves; bringing the free ends of the three leaves together such that the first leaf and a second leaf of the three leaves form a body having a channel for receiving an underwire, with the cushioning material positioned on the outside of the body, and the third leaf of the three leaves is folded around the cushioning material to capture the cushioning material between the body and the third leaf. By ‘integrated structure having three leaves’, it is meant that there is a one piece structure having three leaves integrally connected to one another.

The cushioning material may be positioned on the first leaf after the first and second leaves have been brought together to form the body, and before the third leaf is folded around the cushioning material.

The three leaf structure may have a T-shaped cross-section prior to the step of bringing the free ends of the leaves together.

Preferably, the step of positioning the cushioning material on the outside of the body further comprises attaching the cushioning material to the body.

The method may further comprise attaching a film to the third leaf prior to bringing the free ends of the leaves together.

The method may further comprise attaching the three free ends of the leaves together.

The present invention may also be directed to a structure for a cushioned underwire having an underwire and a cushioning material.

In a first embodiment the structure comprises a body having a channel for receiving an underwire and a wing member integral with and extending from the body, wherein the wing member is configured to be folded around a portion of the body for capturing a cushioning material positioned between the body and the wing member.

In a second embodiment, the integrated structure comprises three leaves, wherein in use, two of the leaves are brought together to form a body having a channel for receiving the underwire, and the third leaf is folded around at least a portion of the body for capturing a cushioning member positioned between the body and the wing member.

In a third embodiment, the structure comprises an inner sleeve for an underwire and an outer layer, the outer layer being preferably a fabric layer. The inner sleeve comprises a longitudinal body having a channel for receiving an underwire and a protrusion extending from an outer surface of the longitudinal body, the protrusion extending longitudinally. The protrusion preferably extends substantially along the length of the body. The invention also relates to the inner sleeve itself.

The inner sleeve may comprise a second protrusion extending from the outer surface of the longitudinal body, the second protrusion extending longitudinally, where the first and second protrusions are spaced apart on the outer surface of the body. Preferably, the first and second protrusions are parallel.

In a fourth aspect of the present invention, there is provided a cushioned casing for an underwire of a brassiere comprising a cushioning material and a structure for enclosing an underwire and the cushioning material. The structure comprises an inner sleeve and an outer layer. The inner sleeve comprises a longitudinal body having a channel for receiving an underwire and a protrusion extending from an outer surface of the longitudinal body, the protrusion extending longitudinally. The cushioning material is positioned on the outer surface of the body adjacent the protrusion and the outer layer surrounds the cushioning material and at least a portion of the inner sleeve, such that the cushioning material is captured between the inner sleeve and the outer layer. The outer layer is preferably a fabric layer.

The protrusion preferably extends substantially along the full length of the longitudinal body.

In one embodiment of a cushioned casing, the inner sleeve may comprise a second protrusion extending from the outer surface of the longitudinal body, the second protrusion extending longitudinally. The first and second protrusions are spaced apart on the body and the cushioning material is positioned on the outside surface of the body between the first and second protrusions.

One or both of the protrusions and the outer surface of the body may be shaped to accommodate the shape of the cushioning material.

The cushioned casing may further comprise a film layer positioned between the outer layer and the cushioning material.

Preferably, the outer layer wraps substantially all the way around the outer surface of the combined inner sleeve and cushioning material to enclose the cushioning material and substantially enclose the inner sleeve.

In a fifth aspect of the invention, there is provided a method for manufacturing a cushioned casing for an underwire of a brassiere, the method comprising providing an inner sleeve comprising a longitudinal body having a channel for receiving an underwire and a protrusion extending from an outer surface of the longitudinal body, the protrusion extending longitudinally. The method further comprises placing a cushioning material on the outer surface of the body adjacent the protrusion and wrapping an outer layer around the cushioning material and at least a portion of the inner sleeve, such that the cushioning material is captured between the inner sleeve and the outer layer. The outer layer is preferably a fabric layer.

The inner sleeve may comprise a second protrusion extending from the outer surface of the longitudinal body, the second protrusion extending longitudinally. The method then further comprises positioning the cushioning material on the outside surface of the body between the first and second protrusions.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the present invention will now be described with reference to the accompanying drawings, in which:

FIG. 1 shows a general brassiere;

FIG. 2 shows a perspective view of a breast cup incorporating a cushioned underwire casing in accordance with a first embodiment of the invention;

FIG. 3 shows, in part (a), a structure for a cushioned underwire casing, in parts (b) and (c), a method of manufacturing a cushioned underwire casing incorporating the structure, and in part (c), a finished cushioned underwire casing including an underwire, in accordance with the first embodiment of the invention;

FIG. 4 shows, in part (a), a structure for a cushioned underwire casing, in parts (b) and (c), a method of manufacturing a cushioned underwire casing incorporating the structure, and in part (c), a finished cushioned underwire casing including an underwire, in accordance with a second embodiment of the invention;

FIG. 5 shows, in part (a), a structure for a cushioned underwire casing, in parts (b) and (c), a method of manufacturing a cushioned underwire casing incorporating the structure, and in part (c), a finished cushioned underwire casing including an underwire, in accordance with a third embodiment of the invention;

FIG. 6 shows, in part (a), a structure for a cushioned underwire casing, in parts (b) and (c), a method of manufacturing a cushioned underwire casing incorporating the structure, and in part (c), a finished cushioned underwire casing including an underwire, in accordance with a fourth embodiment of the invention.

FIG. 7 shows, in part (a), an inner sleeve and, in part (b), a cushioned underwire casing including an underwire, in accordance with a fifth embodiment of the invention;

FIG. 8 shows, in part (a), an inner sleeve and, in part (b), a cushioned underwire casing including an underwire, in accordance with a sixth embodiment of the invention;

FIG. 9 shows, in part (a), an inner sleeve and, in part (b), a cushioned underwire casing including an underwire, in accordance with a seventh embodiment of the invention.

DETAILED DESCRIPTION

FIG. 1 depicts a general brassiere 10 comprising two breast cups 11 and two underwire regions 12, which will be discussed in further detail in relation to the present invention.

The present invention relates to cushioned underwire casings and their methods of manufacture. The cushioned underwire casings are designed to be attached to the underwire regions 12 of a brassiere 10 and to receive an underwire, in order to provide shape and support for the breast cups 11. In this regard, the present invention also relates to a cushioned underwire, a breast cup, and a brassiere that incorporates a cushioned underwire casing according to the present invention.

FIG. 2 shows a perspective view of a breast cup 11 comprising an underwire region 12 with an attached cushioned underwire casing 100 in accordance with a first embodiment of the invention. In FIG. 2, the breast cup comprises two fabric-foam laminate layers, comprising an inner foam layer 13 with a fabric layer 13′ laminated to the surface that contacts a wearer of the brassiere and an outer foam layer 14 with a fabric layer 14′ laminated on the surface that faces away from a wearer of the bra. However, any layer arrangement may be used comprising one or more layers of fabric, foam or fabric-foam laminates.

The cushioned underwire casing 100 of FIG. 2 comprises a cushioning material 160 and a structure 170 that captures the underwire 150 and the cushioning material 160, as will be described in greater detail with reference to FIG. 3. The cushioned underwire casing 100 is preferably attached to the underwire region 12 by sewing it to the breast cup 11 along sew lines 190. The cushioned underwire casing 100 casing is sewn to the side which faces the wearer, with the cushioning material 160 being positioned between the wearer and the channel for receiving the underwire 150 to provide cushioning of an inserted underwire 150. It is preferable to attach the cushioned underwire casing to the breast cup before inserting an underwire 150, because it makes the sewing step easier.

The cushioning material 160 can be any suitable cushioning material, by way of non-limiting example it could be foam, gel, silicone or thermoplastic rubber, or a combination of suitable materials.

In FIG. 2, the cushioned underwire casing that is attached to the underwire region 12 of the breast cup 11 can be any of the cushioned underwire casings 100, 200, 300, 400, 500, 600, 700 of the present invention, and not just that of the first embodiment 100, as will become apparent from the detailed description of the cushioned underwire casings 100, 200, 300, 400, 500, 600, 700 and their methods of manufacture.

FIG. 3 illustrates in greater detail the cushioned underwire casing 100 of the first embodiment and its method of manufacture. The structure 170 for the cushioned underwire casing 100 is preferably a fabric structure. The structure 170 comprises a body 171 having a channel 172 for receiving the underwire 150 and a wing member 173 integral with and extending from the body 171. The wing member 173 is configured to be folded around (as shown by arrow A) a portion of the body 171 for capturing the cushioning material 160 positioned between the body 171 and the wing member 173, as will be described in detail in relation to a method for manufacturing the cushioned underwire casing 100.

A method for manufacturing the cushioned underwire casing comprises, with reference to part (b) of FIG. 3, positioning the cushioning material 160 over the outside of the body 171 of the structure 170, folding the wing member 173 around the cushioning material 160 (as shown by arrow A) to capture the cushioning member 160 between the body 171 and the wing member 173. Preferably, the cushioning material is fixed to the body 171 of the structure 170 by any suitable means. By way of a non-limiting example, if the cushioning material 160 is foam, the cushioning material 160 can be attached to the body 171 by way of heat press molding, preferably with adhesives added, or if the cushioning material is gel, silicone or thermoplastic rubber, the attaching can be accomplished by way of injection moulding. As illustrated in FIG. 3, the cushioning material 160 is positioned on the outside of the body 171 and is captured between the body 171 and the wing member 173.

Turning to part (c) of FIG. 3, the cushioned underwire casing 100 is sewn to the breast cup 11 along stitches lines 190 (for clarity, the breast cup 11 is not illustrated) to attach the cushioned underwire casing 100 to the breast cup 11, as well as attaching the wing member 173 to the body 171. The underwire 150 is then inserted into the channel 172 of the body 171. Although it is preferable to insert the underwire after the cushioned underwire casing 100 has been sewn to the breast cup 11, the underwire 150 could be inserted before sewing. The finished cushioned underwire casing 100 with inserted underwire 150 is depicted in part (c) of FIG. 3.

As shown in FIG. 3, parts (b) an (c), the cushioned underwire casing preferably comprises a film layer 180. In this embodiment, a film member is attached to the wing member 173, on the side of the wing member 173 that contacts the cushioning material 160. The wing member 173 with attached film 180 is then folded in the direction of arrow A to capture the cushioning material between the body 171 and wing member 173, with the film 180 positioned therebetween. The film 180 may be advantageous where the cushioning material 160 is greasy, as it will prevent the greasy cushioning material 160 showing through the wing member 173 especially if the wing member 173 is made of fabric.

FIG. 4 shows a second embodiment of a cushioned underwire casing 200 of the present invention. The cushioned underwire casing 200 is substantially the same as that of the first embodiment, with like reference numerals used to indicate like parts. The difference between the cushioned underwire casing of the second embodiment 200 and that of the first 100 is in the structure for capturing the underwire and cushioning material. In the second embodiment, the structure 270 comprises two protrusions 274 that extend from the body part 271. Preferably, the protrusions 274 are integral with the body part and are formed when the structure is woven. The protrusions 274 are sized and shaped such that the cushioning material 260 can be positioned between the protrusions 274, as shown in parts (b) and (c) of FIG. 4. As with the first embodiment, the cushioning material 260 is preferably attached to the body 271. The wing member 273 is folded around the protrusions 274 and the cushioning material 260 to form the cushioned underwire casing 200. The protrusions 274 provide the cushioned underwire casing with a more rectangular and less bulging cross-section than that of the first embodiment shown in FIG. 3. The protrusions 274 may be of a lower height than the cushioning material 260, such that the cushioning material extends above the protrusions 274, so that the protrusions 274 are not felt by the wearer. As illustrated in FIG. 4, the cushioning material 260 is positioned on the outside of the body 271 and is captured between the body 271 and the wing member 273.

The cushioned underwire casing 200 is sewn to a breast cup 11 along sew lines 290 to attach the casing 200 to the breast cup 11 and also preferably to attach the wing member 273 to the protrusions 274. Thus, each sew line 290 preferably passes through the breast cup 11, the wing member 273 and one of the protrusions 274. The underwire 250 is then inserted into the cushioned underwire casing 200, as shown in part (c) of FIG. 3. As with the first embodiment 100, a film 280 may also be provided.

FIG. 5, part (c), shows a third embodiment of a cushioned underwire casing 300 comprising an underwire 350 in accordance with the present invention. The cushioned underwire casing 300 is substantially the same as that of the second embodiment 200, but the structure 370 comprises a single protrusion 374 extending from the body 371 of the structure 370. As with the second embodiment 200, the protrusion 374 is preferably integral with the body 371 and is formed when the structure 370 is woven. As can be seen from part (c) of FIG. 5, the cushioned underwire casing 300 of the third embodiment has a more sloped cross-section, sloping from a higher side to a lower side. Preferably, the higher side is sewn to the innermost edge of the underwire region 12 of the breast cup 11 and the lower side is sewn to the outermost edge of the underwire region 12, such that the visible edge (i.e. the outermost edge) of the cushioned underwire casing 300 when the brassiere 10 is worn is the thinnest, reducing the visible bulk of the cushioned underwire casing 300 whilst also reducing the bulging that results from the cushioning material 360. As with the third embodiment, the sewing of the casing 300 to the breast cup 11 preferably also sews the wing member 373 to the protrusion 374. As with the first 100 and second 200 embodiments of the cushioned underwire casing, a film 380 can also be provided. As illustrated in FIG. 5, the cushioning material 360 is positioned on the outside of the body 371 and is captured between the body 371 and the wing member 373.

Although FIG. 5 illustrates a single protrusion extending on the left side only, i.e. the side that is further away from the wing member, a variation is that the single protrusion extends on the right side only, i.e. the side that is closer to the wing member, though such variation is not shown in the figures.

A fourth embodiment of the cushioned underwire casing 400 of the present invention is shown in part (c) of FIG. 6, where the casing 400 includes an underwire 450. In the fourth embodiment, the structure 470 is a three leafed structure comprising three integrated leaves 471 a, 471 b, 473. Preferably, but not necessarily, the structure 470, before incorporation into the cushioned underwire casing 400, has a T-shaped cross-section as seen in part (a) of FIG. 6. The method of manufacturing the cushioned underwire casing shown in part (c) of FIG. 6 is now described with reference to part (b) and (c) of FIG. 6. With reference to part (b), a cushioning material is attached to a first leaf 471 a of the structure 470. The attachment may be achieved as described in relation to the first embodiment. Each leaf has an end that is attached to the other leaves and a free end. The method comprises bringing the free ends of the leaves together, as shown by arrows B and C in part (b). The leaves are brought together to form, from the first 471 a and second leaves 471 b, a body 471 upon which the cushioning material is attached, and a wing member which is the third leaf 473. The wing member or third leaf 473 is folded around the cushioning material 460 to capture the cushioning material 460 between the body 471 a, 471 b and the third leaf 473.

The order of attaching the cushioning material 460 to the first leaf 471 a and bringing the leaves together can be changed without departing from the scope of the invention. For example, the free ends of the first and second leaves 471 a, 471 b can be brought together (as shown by arrow C) to form the body 471, and the cushioning material 460 can then be attached to the outside of the body (i.e. to the first leaf 471 a). Thereafter, the third leaf 473 can be folded around the cushioning material 460 in the direction of arrow B to capture the cushioning material 460 between the body (the first leaf 471 a of the body 471) and the third leaf 413.

In addition, a film 480 may be provided. If provided, it is attached to the third leaf 473 prior to the free end of the third leaf 473 being brought together with the free ends of the first and second leaves 471 a, 471 b. The film 480 is attached to the side of the leaf that contacts the cushioning material to provide a barrier against a greasy cushioning material, as described previously.

As illustrated in FIG. 6, the cushioning material 460 is positioned on the outside of the body 471 and is captured between the body 471 and the wing member 473.

As with the previous embodiments, the cushioned casing for an underwire is sewn to an underwire region 12 of a breast cup 11 along sew lines 490. The sew lines 490 preferably pass through all three free ends of the leaves 471 a, 471 b, 473 on one side of the cushioning member 460 and the joined leaves on the other side of the cushioning material 460. Thus, the sewing of the casing 400 to the breast cup 11 also results in attaching the free ends of the leaves together to form a secure underwire channel 472 and to securely capture the cushioning material between the body 471 and third leaf or wing member 473. The underwire 450 is then inserted into the cushioned underwire casing to complete the cushioned underwire.

Although the protrusions have been described and are illustrated with respect to the second and third embodiments only, the fourth embodiment could be provided with one or more protrusions also, if desired.

As specified above, the film 180, 280, 380, 480 is an optional feature of all four embodiments of the cushioned underwire casing 100, 200, 300, 400. The film 180, 280, 380, 480 is flexible and is preferably a plastic film, or more preferably a polyurethane film.

Although the cushioning material 160, 260, 360, 460 is preferably attached to the outside of the body 171, 271, 371, 471 of the structure 170, 270, 370, 470 in all of the described embodiments, the cushioning material could instead be placed on the outside of body without attachment, the cushioning material being held in place by being captured between the body 171, 271, 371, 471 and the wing member 173, 273, 373, 473.

Furthermore, as detailed above, the cushioned underwire casing 100, 200, 300, 400 is preferably sewn to the breast cup 11 before the underwire 150, 250, 350, 450 is inserted into the casing. However, if desired, the underwire 150, 250, 350, 450 can be inserted into the casing 100, 200, 300, 400 prior to the sewing of the casing to the breast cup 11.

Although the preferred embodiments describe the cushioned underwire casing 100, 200, 300, 400 being sewn to the breast cup 11, other suitable attachment means can be provided to attach the cushioned underwire casing 100, 200, 300, 400 to the breast cup 11 and to attach the wing member 173, 273, 373, 473 to the body/protrusions 171, 274, 374, 471, such as adhesive. Furthermore, the cushioned underwire casing 100, 200, 300, 400 need not be attached to the breast cup 11 in the same step as attaching the wing member 173, 273, 373, 473 to the body/protrusion 171, 274, 374, 471. If desired, the wing member 173, 273, 373, 473 can be attached to the body/protrusion 171, 274, 374, 471 before the cushioned underwire casing 100, 200, 300, 400 is attached to the breast cup 11.

The structure 170, 270, 370, 470 is preferably a fabric structure. The integrated structure 170, 270, 370, 470 is preferably woven to produce a body 171, 271, 371 integral with a wing member 171, 271, 371 or three integrated leaves 471 a, 471 b, 473.

FIGS. 7-9 show, in part (a), inner sleeves 570, 670, 770 and, in part (b), cushioned underwire casings 500, 600, 700 including those inner sleeves 570, 670, 770, in accordance with fifth, sixth and seventh embodiments of the invention.

With reference to FIG. 7, part (a), in one embodiment, the inner sleeve 570 has a body 571 comprising an underwire channel 572 for receiving an underwire and a protrusion 574 extending from an outer surface of the body 571. The protrusion 574 preferably extends longitudinally along a substantial portion of the length of the longitudinal body 571. As with the protrusions of the cushioned underwire structures previously discussed, the protrusion 574 is preferably integral with the body 571 of the inner sleeve 570, being formed when the inner sleeve 570 is woven.

The protrusion 574 is preferably sized and shaped to provide support to the cushioning material 560 (shown in 7(b)) and to retain it in place. The protrusion 574 can have a concave shape to accommodate the convex shape of the cushioning material 560. To manufacture the cushioned underwire casing 500 of the fifth embodiment of the invention (as shown in FIG. 7( b)), the cushioning material 560 is preferably attached to the body 571 of the inner sleeve 570. The cushioning material may be made from foam, gel, silicone, TPR (thermoplastic rubber), or any other suitable material. It can be attached to the inner sleeve 570 by heat press moulding (for foam) or injection moulding (for gel/silicone/TPR) or by any other suitable means.

An outer layer 573 is wrapped around the inner sleeve 570 and cushioning material 560 to capture the cushioning material between the inner sleeve 570 and outer layer 573. The outer layer 573 preferably overlaps at least the two longitudinal edges of the body 571. The outer layer 573 is preferably a fabric layer.

The protrusion 574 provides the cushioned underwire casing 500 with a less bulging cross-section than that of the first embodiment shown in FIG. 3. The protrusion 574 may be of a lower height than the cushioning material 560, such that the cushioning material extends above the protrusion 574, so that the protrusion 574 is not felt by the wearer.

The cushioned casing 500 of the fifth embodiment therefore comprises a two-part structure for capturing an underwire and the cushioning material, the first part being the inner sleeve 570 and the second part being the outer layer 573.

Preferably, the cushioned underwire casing 500 is sewn to a breast cup 11 along sew lines 590 to attach the outer layer 573 to the inner sleeve 570 and to attach the cushioned underwire casing 500 to the breast cup 11. Thus, each sew line 590 preferably passes through the breast cup 11, the outer layer 573, the body 571, and the protrusion 574 (where present). The underwire 550 is then inserted into the cushioned underwire casing 500, as shown in part (b) of FIG. 7. Alternatively, the outer layer 573 may be first attached to the inner sleeve 570 (by sew lines 590 or other means such as adhesive), prior to the cushioned underwire casing 500 being attached to the breast cup 11 (again by sewing or other means such as adhesive).

As with previous embodiments of cushioned underwire casings, a film may also be provided between the outer layer (which in previous embodiments was the wing member) and the cushioning material. The film 580 may be adhered to the outer layer 573, so that the outer layer and film are wrapped around the combined inner sleeve 570 and cushioning material 560. Alternatively, the film layer 580 may be wrapped around the combined inner sleeve 570 and cushioning material 560 before the outer layer 573 is then wrapped around, the film 580 and outer layer 573 being attached via the sewing lines 590. The film 580 is preferably a plastic film, or more preferably a polyurethane film.

FIG. 8, part (a), shows another embodiment of an inner sleeve 670 with a longitudinal protrusion 674 extending from the surface of the body 671 and extending longitudinally along the length of the body 671. The protrusion 674 is located along an edge of the outer surface of the body 671 opposite to that shown in FIG. 7 part (a). Other than the location of the protrusion 674, the inner sleeve 670 and the resultant cushioned underwire casing 600 are the same as described for FIG. 7.

FIG. 9 shows, in part (a), an inner sleeve 770 in accordance with another embodiment of the invention and, in part (b), a cushioned underwire casing 700 in accordance with a seventh aspect of the invention. The inner sleeve 770 is substantially the same as that described for FIGS. 7 and 8, however, the inner sleeve 770 comprises two longitudinally extending protrusions 774 positioned on opposite sides of the outer surface of the body 771 of the inner sleeve 770. Similarly, the cushioned underwire casing 700 of the seventh embodiment is substantially as described with respect to FIGS. 7 and 8, with the difference being that the inner sleeve 770 comprises two longitudinal protrusions 774. The protrusions 774 are sized and shaped such that the cushioning material 760 can be positioned between the protrusions 774, as shown in part (b). The protrusions 774 provide the cushioned underwire casing 700 with a more rectangular and less bulging cross-section than that of the first embodiment shown in FIG. 3. The protrusions 774 may be of a lower height than the cushioning material 760, such that the cushioning material extends above the protrusions 774, so that the protrusions 774 are not felt by the wearer. The protrusions 774 and/or outer surface of the body 771 may be shaped to provide a substantially concave shape to match the corresponding convex shape of the cushioning material 760, as shown in parts (a) and (b) of FIG. 9.

The cushioned underwire casing 700 is manufactured in the same way as described with respect to the embodiment of FIG. 7, and is attached to a breast cup in the same way as described with respect to that embodiment also. As with the previous embodiments, the cushioned underwire casing 700 may optionally comprise a film 780 positioned between the outer layer 773 and the cushioning material 760. The film 780 is preferably a plastic film, or more preferably a polyurethane film. The outer layer 773 is preferably a fabric layer.

The structure for capturing the underwire and cushioning material comprises two parts, the first part being the inner sleeve 770 and the second part being the outer layer 773.

It will be appreciated that this description is by way of examples only; alterations and modifications may be made to the described embodiments without departing from the scope of the invention as defined in the claims. 

What is claimed is:
 1. A cushioned casing for an underwire of a brassiere comprising: a cushioning material; a structure for enclosing an underwire and the cushioning material, the structure comprising an inner sleeve and an outer layer; wherein the inner sleeve comprises a longitudinal body having a channel for receiving an underwire and a protrusion extending from an outer surface of the longitudinal body, the protrusion extending longitudinally; wherein the cushioning material is positioned on the outer surface of the body adjacent the protrusion; and wherein the outer layer surrounds the cushioning material and at least a portion of the inner sleeve, such that the cushioning material is captured between the inner sleeve and the outer layer.
 2. The cushioned casing of claim 1, wherein the protrusion extends substantially along the full length of the longitudinal body.
 3. The cushioned casing of claim 2, wherein the inner sleeve comprises a second protrusion extending from the outer surface of the longitudinal body, the second protrusion extending longitudinally; wherein the first and second protrusions are spaced apart; and wherein the cushioning material is positioned on the outside surface of the body between the first and second protrusions.
 4. The cushioned casing of claim 3, wherein one or both of the protrusions and the outer surface of the body is shaped to accommodate the shape of the cushioning material.
 5. The cushioned casing of claim 1, further comprising a film layer positioned between the outer layer and the cushioning material.
 6. The cushioned casing of claim 1, wherein the outer layer wraps substantially all the way around the outer surface of the combined inner sleeve and cushioning material to enclose the cushioning material and substantially enclose the inner sleeve.
 7. A method for manufacturing a cushioned casing for an underwire of a brassiere, the method comprising: providing an inner sleeve comprising a longitudinal body having a channel for receiving an underwire and a protrusion extending from an outer surface of the longitudinal body, the protrusion extending longitudinally; placing a cushioning material on the outer surface of the body adjacent the protrusion; and wrapping an outer layer around the cushioning material and at least a portion of the inner sleeve, such that the cushioning material is captured between the inner sleeve and the outer layer.
 8. The method of claim 7, wherein the inner sleeve comprises a second protrusion extending from the outer surface of the longitudinal body, the second protrusion extending longitudinally, and the method comprises positioning the cushioning material on the outside surface of the body between the first and second protrusions. 